Aqueous coating composition for automotive upholstery

Abstract

The present invention provides a coating composition for automotive upholstery, with which a 1-coat finish of not yet surface-treated (pretreated) plastic materials such as polyolefin materials can be performed, and which is aqueous, and excellent also in chemical resistance. The aqueous coating composition for automotive upholstery comprises a resin emulsion as an essential component, wherein the resin emulsion includes poly(olefin chloride) resin emulsion A and pure acrylic resin emulsion B in a weight ratio (A/B) of 25/75~30/70 in terms of solid content, wherein poly(olefin chloride) resin emulsion A is an emulsion of a poly(olefin chloride) resin having a chlorine content of 22~25 wt % in terms of solid content and a weight-average molecular weight of 60,000~80,000, and wherein pure acrylic resin emulsion B is an emulsion of a pure acrylic resin having a glass transition temperature of not lower than 40° C.

What is claimed is:  
     
       1. An aqueous coating composition for automotive plastic upholstery, comprising: 
       a) a resin emulsion C as an essential component,  
       b) wherein the resin emulsion C comprises maleated poly (olefin chloride) resin emulsion A and pure acrylic resin emulsion B in a weight ratio (A/B) of 25/75-30/70 in terms of solid content;  
       c) wherein the maleated poly (olefin chloride) resin emulsion A is an emulsion of a maleated poly (olefin chloride) resin having a chlorine content of 22-25 wt % in terms of solid content and a weight-average molecular weight of 60,000-80,000;  
       d) wherein the maleated poly (olefin chloride) resin emulsion A comprises an emulsifier, wherein the emulsifier is in the range of 3 to 40 parts by weight of the maleated poly (olefin chloride) resin;  
       e) wherein pure acrylic resin emulsion B is an emulsion of a pure acrylic resin having a glass transition temperature of not lower than 40° C.;  
       f) wherein said pure acrylic resin is a styrene-free acrylic resin;  
       g) wherein the resin emulsion C includes polymer particles of the maleated poly (olefin chloride) resin and polymer particles of the pure acrylic resin and wherein an average particle diameter of the polymer particles is in the range of 0.01 to 10 μm; and  
       h) wherein the maleated poly(olefin chloride) resin of the maleated poly(olefin chloride) polymer particle is free of styrene.  
     
     
       2. An aqueous coating composition for automotive plastic upholstery according to  claim 1 , which is a lacquer paint and further comprises a scaly inorganic powder in a ratio of 60-75 parts by weight per 100 parts by weight of the resin emulsion in terms of solid content. 
     
     
       3. A coating process for automotive upholstery having a plastic base material, comprising the steps of: 
       a) coating an aqueous coating composition onto the plastic base material of the automotive upholstery;  
       b) drying the resultant coating at 60 to 80° C., wherein the resultant coating that has dried has a thickness of 10 to 50 μm;  
       c) wherein the aqueous coating composition comprises:  
       i) a resin emulsion C as an essential component,  
       ii) wherein the resin emulsion C comprises maleated poly (olefin chloride) resin emulsion A and pure acrylic resin emulsion B in a weight ratio (A/B) of 25/75-30/70 in terms of solid content;  
       iii) wherein the maleated poly (olefin chloride) resin emulsion A is an emulsion of a maleated poly (olefin chloride) resin having a chlorine content of 22-25 wt % in terms of solid content and a weight-average molecular weight of 60,000-80,000;  
       iv) wherein the maleated poly (olefin chloride) resin emulsion A comprises an emulsifier, wherein the emulsifier is in the range of 3 to 40 parts by weight of the maleated poly (olefin chloride) resin;  
       v) wherein pure acrylic resin emulsion B is an emulsion of a pure acrylic resin having a glass transition temperature of not lower than 40° C.;  
       vi) wherein said pure acrylic resin is a styrene-free acrylic resin; and  
       vii) wherein the resin emulsion C includes polymer particles of the maleated poly (olefin chloride) resin and polymer particles of the pure acrylic resin and wherein an average particle diameter of the polymer particles is in the range of 0.01 to 10 μm; and  
       d) selecting maleated poly(olefin chloride) resin that is free of styrene for the maleated poly(olefin chloride) resin of the maleated poly(olefin chloride) polymer particle.  
     
     
       4. Automotive upholstery, comprising: 
       a) a plastic base material;  
       b) a coating film on the plastic base material;  
       c) wherein the coating film is formed on the plastic base material by a process including the steps of:  
       i) coating an aqueous coating composition onto the plastic base material of the automotive upholstery;  
       ii) drying the resultant coating at 60 to 80° C., wherein the resultant coating that has dried has a thickness of 10 to 50 μm; and  
       iii) wherein the aqueous coating composition comprises:  
       A) a resin emulsion C as an essential component,  
       B) wherein the resin emulsion C comprises maleated poly (olefin chloride) resin emulsion A and pure acrylic resin emulsion B in a weight ratio (A/B) of 25/75-30/70 in terms of solid content;  
       C) wherein the maleated poly (olefin chloride) resin emulsion A is an emulsion of a maleated poly (olefin chloride) resin having a chlorine content of 22-25 wt % in terms of solid content and a weight-average molecular weight of 60,000-80,000;  
       D) wherein the maleated poly (olefin chloride) resin emulsion A comprises an emulsifier, wherein the emulsifier is in the range of 3 to 40 parts by weight of the maleated poly (olefin chloride) resin;  
       E) wherein pure acrylic resin emulsion B is an emulsion of a pure acrylic resin having a glass transition temperature of not lower than 40° C.;  
       F) wherein said pure acrylic resin is a styrene-free acrylic resin;  
       G) wherein the resin emulsion C includes polymer particles of the maleated poly (olefin chloride) resin and polymer particles of the pure acrylic resin and wherein an average particle diameter of the polymer particles is in the range of 0.01 to 10 μm; and  
       H) wherein the maleated poly(olefin chloride) resin of the maleated poly(olefin chloride) polymer particle is free of styrene.  
     
     
       5. An aqueous coating composition for automotive plastic upholstery, comprising: 
       a) a resin emulsion C as an essential component,  
       b) wherein the resin emulsion C comprises maleated poly (olefin chloride) resin emulsion A and pure acrylic resin emulsion B in a weight ratio (A/B) of 25/75-30/70 in terms of solid content;  
       c) wherein the maleated poly (olefin chloride) resin emulsion A is an emulsion of a maleated poly (olefin chloride) resin having a chlorine content of 22-25 wt % in terms of solid content and a weight-average molecular weight of 60,000-80,000;  
       d) wherein the maleated poly (olefin chloride) resin emulsion A comprises an emulsifier, wherein the emulsifier is in the range of 3 to 40 parts by weight of the maleated poly (olefin chloride) resin;  
       e) wherein pure acrylic resin emulsion B is an emulsion of a pure acrylic resin having a glass transition temperature of not lower than 40° C.;  
       f) wherein said pure acrylic resin is a styrene-free acrylic resin;  
       g) wherein the resin emulsion C includes polymer particles of the maleated poly (olefin chloride) resin and polymer particles of the pure acrylic resin and wherein an average particle diameter of the polymer particles is in the range of 0.01 to 10 μm; and  
       h) wherein the poly(olefin chloride) resin of the maleated poly(olefin chloride) resin is grafted only with maleic acid or maleic anhydride.  
     
     
       6. An aqueous coating composition for automotive plastic upholstery according to  claim 5 , which is a lacquer paint and further comprises a scaly inorganic powder in a ratio of 60-75 parts by weight per 100 parts by weight of the resin emulsion in terms of solid content. 
     
     
       7. A coating process for automotive upholstery having a plastic base material, comprising the steps of: 
       a) coating an aqueous coating composition onto the plastic base material of the automotive upholstery;  
       b) drying the resultant coating at 60 to 80° C., wherein the resultant coating that has dried has a thickness of 10 to 50 μm;  
       c) wherein the aqueous coating composition comprises:  
       i) a resin emulsion C as an essential component,  
       ii) wherein the resin emulsion C comprises maleated poly (olefin chloride) resin emulsion A and pure acrylic resin emulsion B in a weight ratio (A/B) of 25/75-30/70 in terms of solid content;  
       iii) wherein the maleated poly (olefin chloride) resin emulsion A is an emulsion of a maleated poly (olefin chloride) resin having a chlorine content of 22-25 wt % in terms of solid content and a weight-average molecular weight of 60,000-80,000;  
       iv) wherein the maleated poly (olefin chloride) resin emulsion A comprises an emulsifier, wherein the emulsifier is in the range of 3 to 40 parts by weight of the maleated poly (olefin chloride) resin;  
       v) wherein pure acrylic resin emulsion B is an emulsion of a pure acrylic resin having a glass transition temperature of not lower than 40° C.;  
       vi) wherein said pure acrylic resin is a styrene-free acrylic resin; and  
       vii) wherein the resin emulsion C includes polymer particles of the maleated poly (olefin chloride) resin and polymer particles of the pure acrylic resin and wherein an average particle diameter of the polymer particles is in the range of 0.01 to 10 μm; and  
       d) selecting only maleic acid or maleic anhydride as a graft for the poly(olefin chloride) resin of the maleated poly(olefin chloride) resin.  
     
     
       8. Automotive upholstery, comprising: 
       a) a plastic base material;  
       b) a coating film on the plastic base material;  
       c) wherein the coating film is formed on the plastic base material by a process including the steps of:  
       i) coating an aqueous coating composition onto the plastic base material of the automotive upholstery;  
       ii) drying the resultant coating at 60 to 80° C., wherein the resultant coating that has dried has a thickness of 10 to 50 μm; and  
       iii) wherein the aqueous coating composition comprises:  
       A) a resin emulsion C as an essential component,  
       B) wherein the resin emulsion C comprises maleated poly (olefin chloride) resin emulsion A and pure acrylic resin emulsion B in a weight ratio (A/B) of 25/75-30/70 in terms of solid content;  
       C) wherein the maleated poly (olefin chloride) resin emulsion A is an emulsion of a maleated poly (olefin chloride) resin having a chlorine content of 22-25 wt % in terms of solid content and a weight-average molecular weight of 60,000-80,000;  
       D) wherein the maleated poly (olefin chloride) resin emulsion A comprises an emulsifier, wherein the emulsifier is in the range of 3 to 40 parts by weight of the maleated poly (olefin chloride) resin;  
       E) wherein pure acrylic resin emulsion B is an emulsion of a pure acrylic resin having a glass transition temperature of not lower than 40° C.;  
       F) wherein said pure acrylic resin is a styrene-free acrylic resin;  
       G) wherein the resin emulsion C includes polymer particles of the maleated poly (olefin chloride) resin and polymer particles of the pure acrylic resin and wherein an average particle diameter of the polymer particles is in the range of 0.01 to 10 μm; and  
       H) wherein the poly(olefin chloride) resin of the maleated poly(olefin chloride) resin is grafted only with maleic acid or maleic anhydride.